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WO2025029404A1 - Gas filter element, filter device and method of use - Google Patents

Gas filter element, filter device and method of use Download PDF

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Publication number
WO2025029404A1
WO2025029404A1 PCT/US2024/035266 US2024035266W WO2025029404A1 WO 2025029404 A1 WO2025029404 A1 WO 2025029404A1 US 2024035266 W US2024035266 W US 2024035266W WO 2025029404 A1 WO2025029404 A1 WO 2025029404A1
Authority
WO
WIPO (PCT)
Prior art keywords
channels
inlet
outlet channels
gas
gas filter
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/035266
Other languages
French (fr)
Inventor
Keith Rekczis
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Pall Corp
Original Assignee
Pall Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pall Corp filed Critical Pall Corp
Publication of WO2025029404A1 publication Critical patent/WO2025029404A1/en
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2422—Mounting of the body within a housing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2474—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the walls along the length of the honeycomb
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
    • B01D46/249—Quadrangular e.g. square or diamond
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features
    • F01N13/011—Exhaust or silencing apparatus characterised by constructional features having two or more purifying devices arranged in parallel
    • F01N13/017—Exhaust or silencing apparatus characterised by constructional features having two or more purifying devices arranged in parallel the purifying devices are arranged in a single housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825—Ceramics
    • F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N9/00—Electrical control of exhaust gas treating apparatus
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/30—Honeycomb supports characterised by their structural details

Definitions

  • An aspect of the invention provides a gas filter element, comprising a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded by 4 slotted outlet channels; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of slotted outlet channels; the plurality of inlet channels and the plurality of slotted outlet channels having common porous walls.
  • a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded on 2 opposing sides by 2 slotted outlet channels; each of the 771291 2 plurality of inlet channels and each of the of plurality of slotted outlet channels having an inner tapered cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end; the plurality of inlet channels and
  • a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of outlet channels each have an outlet channel closed at the first end, and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels, the gap extending to the second end; each of the plurality of inlet channels being surrounded by outlet channels, each inlet channel surrounded by outlet channels forming an individual channel unit, each individual channel unit surrounded by the gap extending to the second end, such that adjacent individual channel units do not contact one another; the plurality of inlet channels and the plurality of outlet channels in each individual channel unit having common porous walls.
  • a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of outlet channels each have an outlet channel closed at the first end, and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels along a partial length between the first end and the second end; each of the plurality of inlet channels being surrounded by outlet channels, each inlet channel surrounded by outlet channels forming an individual channel unit, each individual channel unit surrounded by the gap along the partial length between the first end and the second end, wherein adjacent individual channel units are held together by a support bracket; the plurality of inlet channels and the plurality of outlet channels in each individual channel unit having common porous walls.
  • the element has a ratio of inner cross-sectional area of all of the plurality of inlet channels to inner cross-sectional area of all of the plurality of slotted outlet channels of greater than 1 to 1.
  • each of the plurality of inlet channels and each of the plurality of plurality of outlet channels or slotted outlet channels having a tapered inner cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end.
  • a filter device comprising an aspect of the gas filter element mounted to a frame.
  • a filter array is provided, comprising at least one, preferably, two or more, aspects of the filter device arranged in a housing.
  • a filter system is provided, comprising two or more aspects of the filter array, arranged adjacent each other.
  • a method of filtering gas comprises passing gas through an aspect of the gas filter element, the method including passing gas into the inlet channel openings and the inlet channels and through the porous walls into the outlet channels and through the outlet channel openings.
  • the gas passing into the inlet channels includes contaminants that are unable to pass through the porous walls such that the gas passing into the outlet channels and through the outlet channel openings has a reduced level of contaminants, providing a “cleaner” gas than the gas entering the gas filter element.
  • BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) [0013]
  • Figures 1A-1B are drawings showing the flow of gas through aspect of the gas filter element according to aspects of the invention.
  • Figure 1A shows a cross-sectional view through an aspect of the gas filter element, wherein dirty gas enters the open end of an inlet channel at the first end of the element, gas is cleaned as it passes through a common porous wall between the inlet channel and a slotted outlet channel, and clean gas exits the gas filter element through the open end of the slotted outlet channel at the second end of the element.
  • Figure 1B is an enlarged view of the dirty gas entry portion of the gas filter element shown in Figure 1A, showing the dirty gas and clean gas flow paths, inlet channels separated from 771291 4 slotted outlet channels (channels illustrated as having generally rectangularly-shaped channels) by porous walls, also showing the inlet channel having an inner cross-sectional area exceeding the inner cross-sectional area of the slotted outlet channel, wherein walls close off the slotted outlet channels at the first end of the element (walls closing off the inlet channels at the second end of the element not shown).
  • Figures 2A-2I are drawings showing a gas filter element according to an aspect of the invention.
  • Figures 2A and 2B are drawings showing, respectively, isometric views of the gas filter element at the first end (dirty gas entry) and at the second end (clean gas exit).
  • Figures 2C and 2D are drawings showing, respectively, the first end (dirty gas entry) and the second end (clean gas exit) the gas filter element shown in Figures 2A and 2B, wherein the outlet channels are closed at the first end, and the inlet channels are closed at the second end.
  • Figure 2E is a side view of the gas filter element shown in Figures 2A and 2B.
  • Figure 2F is a drawing showing a horizontal cross-sectional view of the element along line 2F-2F of Figure 2E, also showing 4 slotted outlet channels surrounding, and adjacent to, the 4 sides of each inlet channel, and supports at the intersection of the slotted outlet channels, in a repeating pattern.
  • Figure 2G is a drawing showing a vertical cross-sectional view of the element along line 2G-2G of Figure 2E
  • Figure 2H is a drawing showing an enlarged view of detail 2H (open end outlet channels) shown in Figure 2G
  • Figure 2I is a drawing showing an enlarged view of detail 2I (closed end outlet channels) shown in Figure 2G.
  • Figures 3A-3I are drawings showing a gas filter element according to another aspect of the invention, wherein the illustrated aspect includes tapered flow channels, each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having a tapered inner cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end.
  • Figures 3A and 3B are drawings showing, respectively, isometric views of the gas filter element at the first end (dirty gas entry) and at the second end (clean gas exit).
  • Figures 3C and 3D are drawings showing, respectively, the first end (dirty gas entry) and the second end (clean gas exit) the gas filter element shown in Figures 3A and 3B, wherein the outlet channels are closed at the first end, and the inlet channels are closed at the second end.
  • Figure 3E is a side view of the filter element shown in Figures 3A and 3B.
  • Figure 3F is a drawing showing a horizontal cross-sectional view of the element along line 3F-3F of Figure 3E, also showing 2 slotted outlet channels surrounding, and adjacent to, 2 opposing sides of each inlet channel, and supports at the intersection of the slotted outlet channels, in a repeating pattern.
  • Figure 3G is a drawing showing a vertical cross-sectional view of the element along line 3G-3G of Figure 3E
  • Figure 3H is a drawing showing an enlarged view of detail 3H (open end outlet channels) shown in Figure 3G
  • Figure 3I is a drawing showing an enlarged view of detail 3I (closed end outlet channels) shown in Figure 3G.
  • Figures 4A-4I are drawings showing a gas filter element according to another aspect of the invention, wherein each inlet channel surrounded by outlet channels forms an individual channel unit, each individual channel unit surrounded by a gap, such that adjacent individual channel units do not contact one another.
  • Figures 4A and 4B are drawings showing, respectively, isometric views of the gas filter element at the first end (dirty gas entry) and at the second end (clean gas exit).
  • Figures 4C and 4D are drawings showing, respectively, the first end (dirty gas entry) and the second end (clean gas exit) the gas filter element shown in Figures 4A and 4B, wherein the outlet channels are closed at the first end, and the inlet channels are closed at the second end.
  • Figure 4E is a side view of the gas filter element shown in Figures 4A and 4B.
  • Figure 4F is a drawing showing a horizontal cross-sectional view of the element along line 4F-4F of Figure 4E, also showing outlet channels surrounding, and adjacent to, inlet channels, inlet channels surrounded by outlet channels forming individual channel units in a repeating pattern, each individual channel unit surrounded by a gap, such that adjacent individual channel units do not contact one another.
  • Figure 4G is a drawing showing a vertical cross-sectional view of the element along line 4G-4G of Figure 4E
  • Figure 4H is a drawing showing an enlarged view of detail 4H (open end outlet channels) shown in Figure 4G
  • Figure 4I is a drawing showing an enlarged view of detail 4I (closed end outlet channels) shown in Figure 4G.
  • Figures 5A-5I are drawings showing a gas filter element according to yet another aspect of the invention, wherein each inlet channel surrounded by outlet channels forms an individual channel unit, each individual channel unit surrounded by a gap along a partial length from the first end to the second end, wherein adjacent individual channel units contact 771291 6 one another by at least one support bracket the first end and the second end of the element.
  • Figures 5A and 5B are drawings showing, respectively, isometric views of the gas filter element at the first end (dirty gas entry) and at the second end (clean gas exit).
  • Figures 5C and 5D are drawings showing, respectively, the first end (dirty gas entry) and the second end (clean gas exit) the gas filter element shown in Figures 5A and 5B, wherein the outlet channels are closed at the first end, and the inlet channels are closed at the second end.
  • Figure 5E is a side view of the gas filter element shown in Figures 5A and 5B.
  • Figure 5F is a drawing showing a horizontal cross-sectional view of the element along line 5F-5F of Figure 5E, through the support bracket connecting individual channel units, also showing outlet channels surrounding, and adjacent to, inlet channels, inlet channels surrounded by outlet channels forming individual channel units in a repeating pattern, wherein there are gaps along partial lengths of the first end to the second end (above and/or below the support bracket[s]).
  • Figure 5G is a drawing showing a vertical cross-sectional view of the element along line 5G-5G of Figure 5E, also showing 3 vertically arranged support brackets
  • Figure 5H is a drawing showing an enlarged view of detail 5H (open end outlet channels) shown in Figure 5G
  • Figure 5I is a drawing showing an enlarged view of detail F (closed end outlet channels) shown in Figure 5I.
  • Figures 6A-6E are drawings showing aspects of gas filter devices comprising gas filter elements mounted to a frame, also showing an aspect of a filter array comprising a plurality of gas filter devices arranged in a housing, also showing an aspect of a gas filter system comprising an aspect of a filter array, the system including a blowback duct associated with the housing.
  • Figure 6A is top view of a gas filter system with the top wall of the housing removed;
  • Figure 6B is a view of the system shown in Figure 6A along section 6B-6B,
  • Figure 6C is a view of the system shown in Figure 6A along section 6C-6C;
  • Figure 6D is a view of the system shown in Figure 6C showing an enlarged view of detail 6D;
  • Figure 6E is a top view of the gas filter system shown in Figure 6A with the top wall of the housing present.
  • An aspect of the invention provides a gas filter element, comprising a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded by 4 slotted outlet channels; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of slotted outlet channels; the plurality of inlet channels and the plurality of slotted outlet channels having common porous walls.
  • a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded on 2 opposing sides by 2 slotted outlet channels; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner tapered cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end; the plurality of inlet channels and the plurality
  • each of the plurality of inlet channels and each of the plurality of plurality of outlet channels have an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of outlet channels.
  • each of the plurality of inlet channels have an inner cross-sectional area equal to the inner cross-sectional area of each of the plurality of outlet channels.
  • the element has a ratio of inner cross-sectional area of all of the plurality of inlet channels to inner cross-sectional area of all of the plurality of slotted outlet channels of greater than 1 to 1, e.g., 1.4 to 1; 5 to 1, 10 to 1, 14 to 1.
  • the element has a ratio of inner cross-sectional area of all of the plurality of inlet channels to inner cross-sectional area of all of the plurality of slotted outlet channels of 1 to 1.
  • each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having a tapered inner cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end.
  • a filter device comprising an aspect of the gas filter element mounted to a frame.
  • a filter array comprising at least one, preferably, two or more, aspects of the filter device arranged in a housing.
  • a filter system is provided, comprising two or more aspects of the filter array, arranged adjacent each other.
  • a method of filtering gas comprises passing gas through an aspect of the gas filter element, the method including passing gas into the inlet channel openings and the inlet channels and through the porous walls into the outlet channels and through the outlet channel openings.
  • the gas passing into the inlet channels includes contaminants that are unable to pass through the porous walls such that the gas passing into the outlet channels and through the outlet channel openings has a reduced level of contaminants, providing a “cleaner” gas than the gas entering the gas filter element.
  • the outlet channels and slotted outlet channels are generally more narrow (e.g., smaller cross-sectional area) than the inlet channels (e.g., having a larger cross-sectional area), a higher pressure differential is provided, imparting more separation between the gas and contaminants.
  • a desirable pressure differential can be additionally provided in those aspects having tapered channels.
  • dirty gas enters the open end of an inlet channel at the first end of the element, gas is cleaned as it passes through a common porous wall between the inlet channel and an outlet channel, and clean gas exits the gas filter element through the open end of the outlet channel at the second end of the element.
  • dirty gas enters the open end 111A of an inlet channel 111 at the first end 101 of the gas filter element 500, gas is cleaned as it passes through a common porous wall 130 between the inlet channel 111 and an outlet channel 112, and clean gas exits the gas filter element through the open end 122A of the outlet channel at the second end 102 of the gas filter element.
  • the gas filter element 500 comprises a first end 101 and a second end 102, having a plurality of inlet channels 111 and a plurality of slotted outlet channels 122 between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels 111 each have an inlet channel opening 111A at the first end, and are closed 111B at the second end, and the plurality of slotted outlet channels 122 each have a slotted outlet channel opening 122A (illustrated as having a generally rectangularly-shaped slot opening) at the second end, and are closed 122B at the first end, each of the plurality of inlet channels being surrounded by 4 slotted outlet channels (see, for example, Fig.2F); each of the plurality of inlet channels and each
  • a support 150 is present along the intersections of the slotted outlet channels.
  • both the slotted outlet channels 122 illustrated as having generally rectangularly-shaped channels; see also, Figure 1B
  • the inlet channels 111 at the second end 102 are blocked at 122B and 111B. While these blocked ends are structurally similar to, or identical in structure to, porous walls 130, due to less resistance, gas will flow through the open ends and along the inlet and outlet channels, rather than the blocked ends.
  • the openings 111A (inlet channel openings) at the first end 101 are all the same larger size, while the openings 122A (slotted channel openings) at the second end 102 are all the same smaller size.
  • the first end 101 includes a lip 101A, e.g., for mounting to a frame to provide a filter device.
  • a gas filter element can include one or more optional spacers 190 (shown as 2 spacers on each of the 4 sides of the gas filter element near second end 102).
  • the gas filter element 600 comprises a first end 201 and a second end 202, having a plurality of inlet channels 211 and a plurality of slotted outlet channels 222 between the first end and the second end, wherein, in an alternating pattern, the plurality of tapered inlet channels 211 each have an inlet channel opening 211A at the first end, and are closed 211B at the second end, and the plurality of slotted outlet channels 222 each have a slotted outlet channel opening 222A (illustrated as having a generally rectangularly-shaped slot opening) at the second end, and are closed 222B at the first end, each of the plurality of inlet channels being surrounded on 2 opposing sides by 2 slotted outlet channels (see, for example, Fig.3F); each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having a tapered inner cross-sectional area (215, 225, respectively), the tapered inner cross-sectional
  • each of the plurality of inlet channels and each of the plurality of plurality of outlet channels have an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of outlet channels.
  • each of the plurality of inlet channels have an inner cross-sectional area equal to the inner cross-sectional area of each of the plurality of outlet channels.
  • the openings 211A (inlet channel openings) at the first end 201 are all the same larger size, while the openings 222A (slotted channel openings) at the second end 202 are all the same smaller size.
  • the first end 201 includes a lip 201A, e.g., for mounting to a frame to provide a filter device.
  • the gas filter element 700 comprises a first end 301 and a second end 302, having a plurality of inlet channels 311 and a plurality of outlet channels 322 between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels 311 each have an inlet channel opening 311A at the first end, and are closed 311B at the 600e second end, and the plurality of outlet channels 322 each have an outlet channel opening 322A at the second end, and are closed 322B at the first end, each outlet channel 322 forming a gap 375 between adjacent inlet channels 311, the gap extending to the second end; each of the plurality of inlet channels being surrounded by outlet channels, each inlet channel surrounded by outlet channels forming an individual channel unit 390, each individual channel unit surrounded by the gap 375 extending to the second end, such that adjacent individual channel units do not contact one another; each of the plurality of inlet channels and each of the plurality of plurality of plurality
  • the gas filter element 800 comprises a first end 401 and a second end 402, having a plurality of inlet channels 411 and a plurality of outlet channels 422 between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels 411 each have an inlet channel opening 411A at the first end, and are closed 411B at the second end, and the plurality of outlet channels 422 each have an outlet channel opening 422A at the second end, and are closed 422B at the first end, each outlet channel 422 forming at least one gap 475 (illustrated as gaps 475A, 475B, 475C, and 475D) between adjacent inlet channels 411 along a partial length between the second end and the second end (illustrated as separate gaps above and/or below a support bracket 450; illustrated as first support bracket 450A, second support bracket 450B, third support bracket 450C, and fourth support bracket 450D), wherein the gap is
  • both the outlet channels 422 at the first end 401 and the inlet channels 411 at the second end 402 are blocked at 422B and 411B. While these blocked ends are structurally similar to, or identical in structure to, porous 771291 14 walls 430, due to less resistance, gas will through the open ends and along the inlet and outlet channels, rather than the blocked ends.
  • the first end 401 includes a lip 401A, e.g., for mounting to a frame to provide a filter device.
  • the porous walls can have any suitable pore structure, e.g., a pore size (for example, as evidenced by bubble point, or by KL as described in, for example, U.S. Patent 4,340,479, or evidenced by capillary condensation flow porometry), a mean flow pore (MFP) size (e.g., when characterized using a porometer, for example, a Porvair Porometer (Porvair plc, Norfolk, UK), or a porometer available under the trademark POROLUX (Porometer.com; Belgium)), a pore rating, a pore diameter (e.g., when characterized using the modified OSU F2 test as described in, for example, U.S.
  • a pore size for example, as evidenced by bubble point, or by KL as described in, for example, U.S. Patent 4,340,479, or evidenced by capillary condensation flow porometry
  • MFP mean flow pore
  • a porometer for example, a Porvair Porometer
  • Illustrative catalysts suitable for nitrous oxide(s) reduction include, for example, MnOx, Mn-TiO 2 , Cu/Al2O3; illustrative catalysts suitable for sulfur reduction include, for example, Ca(OH)2 and NaHCO 3 , and illustrative catalysts suitable for simultaneous nitrous oxide(s) and sulfur oxide(s) reductions reduction include, for example, Fe2O3.
  • Filter elements can be, for example, formed from ceramics, e.g., silica, and from stainless steel powder, such as 316 low-carbon stainless steel and 310 stainless steel, by a process including sintering.
  • Filter elements according to embodiments of the invention can be monolithic, e.g., manufactured via additive manufacturing (sometimes referred to as “additive layer manufacturing” or “3D printing”).
  • a gas filter device comprising an aspect of the gas filter element mounted to a frame.
  • a gas filter array comprising at least one, preferably, two or more, aspects of the filter device arranged in a housing.
  • the illustrated gas filter array 1000 comprises two or more gas filter devices mounted to a frame 950, arranged in a housing 1015.
  • each of the 3 gas filter arrays 1000 includes 7 gas filter devices 900, each gas filter device including 9 gas filter elements.
  • a gas filter system 2000 is provided (Figure 6E showing an external view of the system 2000; since the rear of the system is typically open, a rear view would be similar to that shown in Figure 6C), comprising at least one gas filter array 1000 comprising two or more aspects of the gas filter device 900, wherein the filter devices are arranged consecutively adjacent each other; preferably, wherein the filter system further comprises a blowback duct 2015.
  • the illustrated aspect of the gas filter system 2000 comprises a filter array 1000 comprising two or more aspects of the filter devices 900 arranged linearly in the housing 1015, and a blowback duct 2015 arranged at one end of the housing, the blowback duct arranged to operate at the second ends 102, 202, 302, 771291 16 402 of the gas filter elements.
  • gas through the blowback duct passes through the outlet channel openings at the second end of each of the gas filter devices in the gas filter array, through the porous walls, and through the inlet channel openings at the first ends 101, 201, 301, 401, dislodging filter cake accumulated on the porous walls in the inlet channels.

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Abstract

A gas filter element comprising: a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded by 4 slotted outlet channels; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of slotted outlet channels.

Description

771291 1 GAS FILTER ELEMENT, DEVICE AND METHOD OF USE BACKGROUND OF THE INVENTION [0001] There is increasing interest in filtering gas, which may including capturing carbon by removing it from a gas such as flue gas (e.g., by capturing carbon dioxide (CO2) emissions from power plants and industrial facilities) in order to, for example, fight climate change. There is a need for improved filters for removing solid contaminants from a fluid, e.g., to protect carbon capture systems and/or there is a need for capturing carbon in gas. [0002] The present invention provides for ameliorating at least some of the disadvantages of the prior art. These and other advantages of the present invention will be apparent from the description as set forth below. BRIEF SUMMARY OF THE INVENTION [0003] An aspect of the invention provides a gas filter element, comprising a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded by 4 slotted outlet channels; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of slotted outlet channels; the plurality of inlet channels and the plurality of slotted outlet channels having common porous walls. [0004] In accordance with another aspect of the invention, a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded on 2 opposing sides by 2 slotted outlet channels; each of the 771291 2 plurality of inlet channels and each of the of plurality of slotted outlet channels having an inner tapered cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end; the plurality of inlet channels and the plurality of slotted outlet channels having common porous walls. [0005] In accordance with another aspect of the invention, a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of outlet channels each have an outlet channel closed at the first end, and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels, the gap extending to the second end; each of the plurality of inlet channels being surrounded by outlet channels, each inlet channel surrounded by outlet channels forming an individual channel unit, each individual channel unit surrounded by the gap extending to the second end, such that adjacent individual channel units do not contact one another; the plurality of inlet channels and the plurality of outlet channels in each individual channel unit having common porous walls. [0006] In accordance with another aspect of the invention, a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of outlet channels each have an outlet channel closed at the first end, and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels along a partial length between the first end and the second end; each of the plurality of inlet channels being surrounded by outlet channels, each inlet channel surrounded by outlet channels forming an individual channel unit, each individual channel unit surrounded by the gap along the partial length between the first end and the second end, wherein adjacent individual channel units are held together by a support bracket; the plurality of inlet channels and the plurality of outlet channels in each individual channel unit having common porous walls. 771291 3 [0007] In some aspects of the gas filter the element has a ratio of inner cross-sectional area of all of the plurality of inlet channels to inner cross-sectional area of all of the plurality of slotted outlet channels of greater than 1 to 1. [0008] Alternatively, or additionally, in some aspects of the gas filter element, each of the plurality of inlet channels and each of the plurality of plurality of outlet channels or slotted outlet channels having a tapered inner cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end. [0009] In another aspect of the invention, a filter device is provided, the filter device comprising an aspect of the gas filter element mounted to a frame. [0010] In yet another aspect of the invention, a filter array is provided, comprising at least one, preferably, two or more, aspects of the filter device arranged in a housing. [0011] In yet another aspect of the invention, a filter system is provided, comprising two or more aspects of the filter array, arranged adjacent each other. [0012] In another aspect, a method of filtering gas comprises passing gas through an aspect of the gas filter element, the method including passing gas into the inlet channel openings and the inlet channels and through the porous walls into the outlet channels and through the outlet channel openings. Typically, the gas passing into the inlet channels includes contaminants that are unable to pass through the porous walls such that the gas passing into the outlet channels and through the outlet channel openings has a reduced level of contaminants, providing a “cleaner” gas than the gas entering the gas filter element. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) [0013] Figures 1A-1B are drawings showing the flow of gas through aspect of the gas filter element according to aspects of the invention. Figure 1A shows a cross-sectional view through an aspect of the gas filter element, wherein dirty gas enters the open end of an inlet channel at the first end of the element, gas is cleaned as it passes through a common porous wall between the inlet channel and a slotted outlet channel, and clean gas exits the gas filter element through the open end of the slotted outlet channel at the second end of the element. Figure 1B is an enlarged view of the dirty gas entry portion of the gas filter element shown in Figure 1A, showing the dirty gas and clean gas flow paths, inlet channels separated from 771291 4 slotted outlet channels (channels illustrated as having generally rectangularly-shaped channels) by porous walls, also showing the inlet channel having an inner cross-sectional area exceeding the inner cross-sectional area of the slotted outlet channel, wherein walls close off the slotted outlet channels at the first end of the element (walls closing off the inlet channels at the second end of the element not shown). [0014] Figures 2A-2I are drawings showing a gas filter element according to an aspect of the invention. Figures 2A and 2B are drawings showing, respectively, isometric views of the gas filter element at the first end (dirty gas entry) and at the second end (clean gas exit). Figures 2C and 2D are drawings showing, respectively, the first end (dirty gas entry) and the second end (clean gas exit) the gas filter element shown in Figures 2A and 2B, wherein the outlet channels are closed at the first end, and the inlet channels are closed at the second end. [0015] Figure 2E is a side view of the gas filter element shown in Figures 2A and 2B. Figure 2F is a drawing showing a horizontal cross-sectional view of the element along line 2F-2F of Figure 2E, also showing 4 slotted outlet channels surrounding, and adjacent to, the 4 sides of each inlet channel, and supports at the intersection of the slotted outlet channels, in a repeating pattern. Figure 2G is a drawing showing a vertical cross-sectional view of the element along line 2G-2G of Figure 2E, Figure 2H is a drawing showing an enlarged view of detail 2H (open end outlet channels) shown in Figure 2G, and Figure 2I is a drawing showing an enlarged view of detail 2I (closed end outlet channels) shown in Figure 2G. [0016] Figures 3A-3I are drawings showing a gas filter element according to another aspect of the invention, wherein the illustrated aspect includes tapered flow channels, each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having a tapered inner cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end. [0017] Figures 3A and 3B are drawings showing, respectively, isometric views of the gas filter element at the first end (dirty gas entry) and at the second end (clean gas exit). Figures 3C and 3D are drawings showing, respectively, the first end (dirty gas entry) and the second end (clean gas exit) the gas filter element shown in Figures 3A and 3B, wherein the outlet channels are closed at the first end, and the inlet channels are closed at the second end. 771291 5 [0018] Figure 3E is a side view of the filter element shown in Figures 3A and 3B. Figure 3F is a drawing showing a horizontal cross-sectional view of the element along line 3F-3F of Figure 3E, also showing 2 slotted outlet channels surrounding, and adjacent to, 2 opposing sides of each inlet channel, and supports at the intersection of the slotted outlet channels, in a repeating pattern. Figure 3G is a drawing showing a vertical cross-sectional view of the element along line 3G-3G of Figure 3E, Figure 3H is a drawing showing an enlarged view of detail 3H (open end outlet channels) shown in Figure 3G, and Figure 3I is a drawing showing an enlarged view of detail 3I (closed end outlet channels) shown in Figure 3G. [0019] Figures 4A-4I are drawings showing a gas filter element according to another aspect of the invention, wherein each inlet channel surrounded by outlet channels forms an individual channel unit, each individual channel unit surrounded by a gap, such that adjacent individual channel units do not contact one another. Figures 4A and 4B are drawings showing, respectively, isometric views of the gas filter element at the first end (dirty gas entry) and at the second end (clean gas exit). Figures 4C and 4D are drawings showing, respectively, the first end (dirty gas entry) and the second end (clean gas exit) the gas filter element shown in Figures 4A and 4B, wherein the outlet channels are closed at the first end, and the inlet channels are closed at the second end. [0020] Figure 4E is a side view of the gas filter element shown in Figures 4A and 4B. Figure 4F is a drawing showing a horizontal cross-sectional view of the element along line 4F-4F of Figure 4E, also showing outlet channels surrounding, and adjacent to, inlet channels, inlet channels surrounded by outlet channels forming individual channel units in a repeating pattern, each individual channel unit surrounded by a gap, such that adjacent individual channel units do not contact one another. Figure 4G is a drawing showing a vertical cross-sectional view of the element along line 4G-4G of Figure 4E, Figure 4H is a drawing showing an enlarged view of detail 4H (open end outlet channels) shown in Figure 4G, and Figure 4I is a drawing showing an enlarged view of detail 4I (closed end outlet channels) shown in Figure 4G. [0021] Figures 5A-5I are drawings showing a gas filter element according to yet another aspect of the invention, wherein each inlet channel surrounded by outlet channels forms an individual channel unit, each individual channel unit surrounded by a gap along a partial length from the first end to the second end, wherein adjacent individual channel units contact 771291 6 one another by at least one support bracket the first end and the second end of the element. [0022] Figures 5A and 5B are drawings showing, respectively, isometric views of the gas filter element at the first end (dirty gas entry) and at the second end (clean gas exit). Figures 5C and 5D are drawings showing, respectively, the first end (dirty gas entry) and the second end (clean gas exit) the gas filter element shown in Figures 5A and 5B, wherein the outlet channels are closed at the first end, and the inlet channels are closed at the second end. [0023] Figure 5E is a side view of the gas filter element shown in Figures 5A and 5B. Figure 5F is a drawing showing a horizontal cross-sectional view of the element along line 5F-5F of Figure 5E, through the support bracket connecting individual channel units, also showing outlet channels surrounding, and adjacent to, inlet channels, inlet channels surrounded by outlet channels forming individual channel units in a repeating pattern, wherein there are gaps along partial lengths of the first end to the second end (above and/or below the support bracket[s]). [0024] Figure 5G is a drawing showing a vertical cross-sectional view of the element along line 5G-5G of Figure 5E, also showing 3 vertically arranged support brackets, Figure 5H is a drawing showing an enlarged view of detail 5H (open end outlet channels) shown in Figure 5G, and Figure 5I is a drawing showing an enlarged view of detail F (closed end outlet channels) shown in Figure 5I. [0025] Figures 6A-6E are drawings showing aspects of gas filter devices comprising gas filter elements mounted to a frame, also showing an aspect of a filter array comprising a plurality of gas filter devices arranged in a housing, also showing an aspect of a gas filter system comprising an aspect of a filter array, the system including a blowback duct associated with the housing. Figure 6A is top view of a gas filter system with the top wall of the housing removed; Figure 6B is a view of the system shown in Figure 6A along section 6B-6B, Figure 6C is a view of the system shown in Figure 6A along section 6C-6C; Figure 6D is a view of the system shown in Figure 6C showing an enlarged view of detail 6D; and Figure 6E is a top view of the gas filter system shown in Figure 6A with the top wall of the housing present. 771291 7 DETAILED OF THE INVENTION [0026] An aspect of the invention provides a gas filter element, comprising a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded by 4 slotted outlet channels; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of slotted outlet channels; the plurality of inlet channels and the plurality of slotted outlet channels having common porous walls. [0027] In accordance with another aspect of the invention, a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded on 2 opposing sides by 2 slotted outlet channels; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner tapered cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end; the plurality of inlet channels and the plurality of slotted outlet channels having common porous walls. [0028] In accordance with another aspect of the invention, a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of outlet channels each have an outlet channel closed at the first end, and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels, the gap extending to the second end; each of the plurality of inlet 771291 8 channels being surrounded by outlet each inlet channel surrounded by outlet channels forming an individual channel unit, each individual channel unit surrounded by the gap extending to the second end, such that adjacent individual channel units do not contact one another; the plurality of inlet channels and the plurality of outlet channels in each individual channel unit having common porous walls. [0029] In accordance with another aspect of the invention, a gas filter element comprises: a first end and a second end, having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of outlet channels each have an outlet channel closed at the first end, and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels along a partial length between the first end and the second end; each of the plurality of inlet channels being surrounded by outlet channels, each inlet channel surrounded by outlet channels forming an individual channel unit, each individual channel unit surrounded by the gap along the partial length between the first end and the second end, wherein adjacent individual channel units are held together by a support bracket; the plurality of inlet channels and the plurality of outlet channels in each individual channel unit having common porous walls. [0030] In typical aspects of the gas filter element, each of the plurality of inlet channels and each of the plurality of plurality of outlet channels have an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of outlet channels. However, in some aspects each of the plurality of inlet channels have an inner cross-sectional area equal to the inner cross-sectional area of each of the plurality of outlet channels. [0031] In some aspects of the gas filter element, the element has a ratio of inner cross-sectional area of all of the plurality of inlet channels to inner cross-sectional area of all of the plurality of slotted outlet channels of greater than 1 to 1, e.g., 1.4 to 1; 5 to 1, 10 to 1, 14 to 1. However, in some other aspects, the element has a ratio of inner cross-sectional area of all of the plurality of inlet channels to inner cross-sectional area of all of the plurality of slotted outlet channels of 1 to 1. 771291 9 [0032] Alternatively, or additionally, in aspects of the gas filter element, each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having a tapered inner cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end. [0033] In another aspect of the invention, a filter device is provided, the filter device comprising an aspect of the gas filter element mounted to a frame. [0034] In yet another aspect of the invention, a filter array is provided, comprising at least one, preferably, two or more, aspects of the filter device arranged in a housing. [0035] In yet another aspect of the invention, a filter system is provided, comprising two or more aspects of the filter array, arranged adjacent each other. [0036] In another aspect, a method of filtering gas comprises passing gas through an aspect of the gas filter element, the method including passing gas into the inlet channel openings and the inlet channels and through the porous walls into the outlet channels and through the outlet channel openings. Typically, the gas passing into the inlet channels includes contaminants that are unable to pass through the porous walls such that the gas passing into the outlet channels and through the outlet channel openings has a reduced level of contaminants, providing a “cleaner” gas than the gas entering the gas filter element. [0037] Advantageously, since the outlet channels and slotted outlet channels are generally more narrow (e.g., smaller cross-sectional area) than the inlet channels (e.g., having a larger cross-sectional area), a higher pressure differential is provided, imparting more separation between the gas and contaminants. A desirable pressure differential can be additionally provided in those aspects having tapered channels. [0038] If desired, aspects of the gas filter elements are suitable for cleaning by backflow, wherein gas is passed through the outlet channel openings at the second end, through the porous walls, and through the inlet channel openings at first end, wherein filter cake accumulating on the porous walls of the inlet channels can be dislodged. [0039] For industrial applications in particular, gas filter elements have excellent mechanical strength, having been tested for over 20,000 blowback cycles and over 200,000 fatigue cycles in laboratory tests. 771291 10 [0040] In some aspects, an individual unit can flex slightly under pressure, advantageously providing for improved cleaning during backflow by loosening some of the accumulated filter cake. [0041] Each of the components of the invention will now be described in more detail below, wherein like components have like reference numbers. [0042] In accordance with aspects of the gas filter according to the invention, dirty gas enters the open end of an inlet channel at the first end of the element, gas is cleaned as it passes through a common porous wall between the inlet channel and an outlet channel, and clean gas exits the gas filter element through the open end of the outlet channel at the second end of the element. [0043] In the illustrated aspect shown in Figures 1A-1B, dirty gas enters the open end 111A of an inlet channel 111 at the first end 101 of the gas filter element 500, gas is cleaned as it passes through a common porous wall 130 between the inlet channel 111 and an outlet channel 112, and clean gas exits the gas filter element through the open end 122A of the outlet channel at the second end 102 of the gas filter element. In the aspect shown in Figure 1B, each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having inner cross-sectional areas 115, 125, respectively. [0044] In the illustrated aspects shown in Figures 2A-2I, the gas filter element 500 comprises a first end 101 and a second end 102, having a plurality of inlet channels 111 and a plurality of slotted outlet channels 122 between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels 111 each have an inlet channel opening 111A at the first end, and are closed 111B at the second end, and the plurality of slotted outlet channels 122 each have a slotted outlet channel opening 122A (illustrated as having a generally rectangularly-shaped slot opening) at the second end, and are closed 122B at the first end, each of the plurality of inlet channels being surrounded by 4 slotted outlet channels (see, for example, Fig.2F); each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner cross-sectional area (115, 125, respectively), each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of slotted outlet channels; the element having a ratio of inner cross-sectional area of all of the plurality of inlet channels to inner cross-sectional area of all of the plurality of slotted outlet channels of greater than 1; the plurality of inlet channels and the plurality of slotted outlet channels having common porous 771291 11 walls 130. In the aspect illustrated in, for Fig.2F, a support 150 is present along the intersections of the slotted outlet channels. [0045] In the aspect shown in, for example, Figures 2B-2D, both the slotted outlet channels 122 (illustrated as having generally rectangularly-shaped channels; see also, Figure 1B) at the first end 101 and the inlet channels 111 at the second end 102 are blocked at 122B and 111B. While these blocked ends are structurally similar to, or identical in structure to, porous walls 130, due to less resistance, gas will flow through the open ends and along the inlet and outlet channels, rather than the blocked ends. [0046] In the illustrated aspect (see, for example, Figures 2C and 2D), the openings 111A (inlet channel openings) at the first end 101 are all the same larger size, while the openings 122A (slotted channel openings) at the second end 102 are all the same smaller size. [0047] In some aspects, the first end 101 includes a lip 101A, e.g., for mounting to a frame to provide a filter device. [0048] In some aspects of any of the gas filter elements, using the gas filter element illustrated in Figure 2A for general reference, a gas filter element can include one or more optional spacers 190 (shown as 2 spacers on each of the 4 sides of the gas filter element near second end 102). [0049] In the illustrated aspects shown in Figures 3A-3I, the gas filter element 600 comprises a first end 201 and a second end 202, having a plurality of inlet channels 211 and a plurality of slotted outlet channels 222 between the first end and the second end, wherein, in an alternating pattern, the plurality of tapered inlet channels 211 each have an inlet channel opening 211A at the first end, and are closed 211B at the second end, and the plurality of slotted outlet channels 222 each have a slotted outlet channel opening 222A (illustrated as having a generally rectangularly-shaped slot opening) at the second end, and are closed 222B at the first end, each of the plurality of inlet channels being surrounded on 2 opposing sides by 2 slotted outlet channels (see, for example, Fig.3F); each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having a tapered inner cross-sectional area (215, 225, respectively), the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end; and the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end; the plurality of inlet channels and the plurality of slotted outlet channels having common porous walls the aspect illustrated in, for example, Fig.3F, a support 250 is present along the intersections of the slotted outlet channels. [0050] In aspects of the gas filter element 600, each of the plurality of inlet channels and each of the plurality of plurality of outlet channels have an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of outlet channels. However, in some other aspects each of the plurality of inlet channels have an inner cross-sectional area equal to the inner cross-sectional area of each of the plurality of outlet channels. [0051] In the aspect shown in, for example, Figures 3B-3D, both the slotted outlet channels 222 at the first end 201 and the inlet channels 211 at the second end 202 are blocked at 222B and 211B. While these blocked ends are structurally similar to, or identical in structure to, porous walls 230, due to less resistance, gas will flow through the open ends and along the inlet and outlet channels, rather than the blocked ends. [0052] In the illustrated aspect (see, for example, Figures 3C and 3D), the openings 211A (inlet channel openings) at the first end 201 are all the same larger size, while the openings 222A (slotted channel openings) at the second end 202 are all the same smaller size. [0053] In some aspects, the first end 201 includes a lip 201A, e.g., for mounting to a frame to provide a filter device. [0054] In the illustrated aspects shown in Figures 4A-4I, the gas filter element 700 comprises a first end 301 and a second end 302, having a plurality of inlet channels 311 and a plurality of outlet channels 322 between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels 311 each have an inlet channel opening 311A at the first end, and are closed 311B at the 600e second end, and the plurality of outlet channels 322 each have an outlet channel opening 322A at the second end, and are closed 322B at the first end, each outlet channel 322 forming a gap 375 between adjacent inlet channels 311, the gap extending to the second end; each of the plurality of inlet channels being surrounded by outlet channels, each inlet channel surrounded by outlet channels forming an individual channel unit 390, each individual channel unit surrounded by the gap 375 extending to the second end, such that adjacent individual channel units do not contact one another; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having 13 an inner cross-sectional area (315, 325, , the plurality of inlet channels and the plurality of outlet channels having common porous walls 330. [0055] In the aspect shown in, for example, Figures 4B-4D, both the outlet channels 322 at the first end 301 and the inlet channels 311 at the second end 302 are blocked at 322B and 311B. While these blocked ends are structurally similar to, or identical in structure to, porous walls 330, due to less resistance, gas will flow through the open ends and along the inlet and outlet channels, rather than the blocked ends. [0056] In some aspects, the first end 301 includes a lip 301A, e.g., for mounting to a frame to provide a filter device. [0057] In the illustrated aspects shown in Figures 5A-5I, the gas filter element 800 comprises a first end 401 and a second end 402, having a plurality of inlet channels 411 and a plurality of outlet channels 422 between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels 411 each have an inlet channel opening 411A at the first end, and are closed 411B at the second end, and the plurality of outlet channels 422 each have an outlet channel opening 422A at the second end, and are closed 422B at the first end, each outlet channel 422 forming at least one gap 475 (illustrated as gaps 475A, 475B, 475C, and 475D) between adjacent inlet channels 411 along a partial length between the second end and the second end (illustrated as separate gaps above and/or below a support bracket 450; illustrated as first support bracket 450A, second support bracket 450B, third support bracket 450C, and fourth support bracket 450D), wherein the gap is not continuous between the first and the second end; each of the plurality of inlet channels being surrounded by outlet channels, each inlet channel surrounded by outlet channels forming an individual channel unit 490, each individual channel unit surrounded by the at least one gap along the partial length between the first end and the second end, wherein adjacent individual channel units are held together by at least one support bracket; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner cross-sectional area (415, 425, respectively), the plurality of inlet channels and the plurality of outlet channels in each individual channel unit having common porous walls 430. [0058] In the aspect shown in, for example, Figures 5B-5D, both the outlet channels 422 at the first end 401 and the inlet channels 411 at the second end 402 are blocked at 422B and 411B. While these blocked ends are structurally similar to, or identical in structure to, porous 771291 14 walls 430, due to less resistance, gas will through the open ends and along the inlet and outlet channels, rather than the blocked ends. [0059] In some aspects, the first end 401 includes a lip 401A, e.g., for mounting to a frame to provide a filter device. [0060] The porous walls can have any suitable pore structure, e.g., a pore size (for example, as evidenced by bubble point, or by KL as described in, for example, U.S. Patent 4,340,479, or evidenced by capillary condensation flow porometry), a mean flow pore (MFP) size (e.g., when characterized using a porometer, for example, a Porvair Porometer (Porvair plc, Norfolk, UK), or a porometer available under the trademark POROLUX (Porometer.com; Belgium)), a pore rating, a pore diameter (e.g., when characterized using the modified OSU F2 test as described in, for example, U.S. Patent 4,925,572), or removal rating media. In some aspects, the porous walls can have a mix of pore structures, e.g., in the range of 5 to 20 micrometers, or a pore structure of, for example, 10 micromenters. [0061] Optionally, in some aspects, the porous walls include one or more catalysts, e.g., for nitrous oxide(s) reductions, sulfur removal and/or sulfur oxide(s) removal. Illustrative catalysts suitable for nitrous oxide(s) reduction include, for example, MnOx, Mn-TiO2, Cu/Al2O3; illustrative catalysts suitable for sulfur reduction include, for example, Ca(OH)2 and NaHCO3, and illustrative catalysts suitable for simultaneous nitrous oxide(s) and sulfur oxide(s) reductions reduction include, for example, Fe2O3. [0062] Filter elements can be, for example, formed from ceramics, e.g., silica, and from stainless steel powder, such as 316 low-carbon stainless steel and 310 stainless steel, by a process including sintering. Other suitable metal powders include, for example, alloys (e.g., HASTELLOY® X, and HAYNES® HR-160® (Haynes International); and Inconel 600), nickel, chromium, tungsten, copper, bronze, aluminum, platinum, iron, magnesium, cobalt, or a combination (including a combination of metals and metal alloys) thereof. [0063] Filter elements according to embodiments of the invention can be monolithic, e.g., manufactured via additive manufacturing (sometimes referred to as “additive layer manufacturing” or “3D printing”). They are typically formed by repeated depositions of a metal powder bound together with an activatable binder (e.g., binder jetting, sometimes referred to as “drop on powder”), typically followed by agglomerating the powder, e.g., by sintering. If present, housing elements, extensions, and other components, can be 771291 15 manufactured together via additive in a continuous operation at substantially the same time. [0064] Any suitable additive manufacturing equipment can be used, and a variety of production 3D printers are suitable and commercially available. [0065] In another aspect of the invention, a gas filter device is provided, the filter device comprising an aspect of the gas filter element mounted to a frame. For example, Figures 6A-6D show a plurality of gas filter devices 900, each gas filter device comprising two or more aspects of a gas filter element (illustrated as gas filter element 500, 600, 700, 800, each illustrated gas filter device including 9 gas filter elements; see, Figure 6A) mounted to a frame 950, wherein the frame includes an opening for receiving the gas filter element, for example, wherein the first end of the gas filter element (the first end can comprise a plate) includes a lip (illustrated as 101A, 201A, 301A, 401A) extending outwardly preventing the first end from passing through the opening in the frame. The lip can be placed in direct contact with the edge of the opening and, if desired, adhered thereto, or, for example, a gasket can be placed between the lip and the edge of the opening. [0066] In yet another aspect of the invention, a gas filter array is provided, comprising at least one, preferably, two or more, aspects of the filter device arranged in a housing. For example, using Figures 6A-6D for reference, the illustrated gas filter array 1000 comprises two or more gas filter devices mounted to a frame 950, arranged in a housing 1015. In the aspect of the gas filter array shown in Figure 6B, each of the 3 gas filter arrays 1000 includes 7 gas filter devices 900, each gas filter device including 9 gas filter elements. [0067] In yet another aspect of the invention, using Figures 6A-6D for reference, a gas filter system 2000 is provided (Figure 6E showing an external view of the system 2000; since the rear of the system is typically open, a rear view would be similar to that shown in Figure 6C), comprising at least one gas filter array 1000 comprising two or more aspects of the gas filter device 900, wherein the filter devices are arranged consecutively adjacent each other; preferably, wherein the filter system further comprises a blowback duct 2015. [0068] Using the aspect shown in Figure 6B for reference, the illustrated aspect of the gas filter system 2000 comprises a filter array 1000 comprising two or more aspects of the filter devices 900 arranged linearly in the housing 1015, and a blowback duct 2015 arranged at one end of the housing, the blowback duct arranged to operate at the second ends 102, 202, 302, 771291 16 402 of the gas filter elements. Thus, gas through the blowback duct passes through the outlet channel openings at the second end of each of the gas filter devices in the gas filter array, through the porous walls, and through the inlet channel openings at the first ends 101, 201, 301, 401, dislodging filter cake accumulated on the porous walls in the inlet channels. [0069] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein. [0070] The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. [0071] Preferred aspects of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred aspects may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically 771291 17 described herein. Accordingly, this includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

771291 18 CLAIM(S): 1. A gas filter element comprising: a first end and a second end, having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein, in an alternating pattern, the plurality of inlet channels each have an inlet channel opening at the first end, and are closed at the second end, and the plurality of slotted outlet channels each have a slotted outlet channel opening at the second end, and are closed at the first end, each of the plurality of inlet channels being surrounded by 4 slotted outlet channels; each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area exceeding the inner cross-sectional area of each of the plurality of slotted outlet channels; the plurality of inlet channels and the plurality of slotted outlet channels having common porous walls. 2. The gas filter element of claims 1, having a ratio of inner cross-sectional area of all of the plurality of inlet channels to inner cross-sectional area of all of the plurality of outlet channels of greater than 1 to 1. 3. A method of filtering gas, the method comprising passing gas through the gas filter element of claim 1 or 2, the method including passing gas into the inlet channel openings and the inlet channels and through the porous walls into the outlet channels and through the outlet channel openings. 4. A gas filter device comprising the gas filter element of claim 1 or 2, mounted to a frame. 5. A gas filter array, comprising at least one gas filter device according to claim 4 arranged in a housing. 771291 19 6. A gas filter system two or more gas filter arrays according to claim 5, arranged adjacent each other.
PCT/US2024/035266 2023-08-02 2024-06-24 Gas filter element, filter device and method of use Pending WO2025029404A1 (en)

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US63/530,391 2023-08-02

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040170803A1 (en) * 2003-02-28 2004-09-02 Ngk Insulators, Ltd. Honeycomb structural body and die for forming honeycomb structural body by extrusion
WO2009069378A1 (en) * 2007-11-28 2009-06-04 Ngk Insulators, Ltd. Method for bonding joint sealing honeycomb structure
US20160069308A1 (en) * 2014-09-04 2016-03-10 Ngk Insulators, Ltd. Honeycomb filter
US20180099241A1 (en) * 2016-10-11 2018-04-12 Ngk Insulators, Ltd. Plugged honeycomb structure

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040170803A1 (en) * 2003-02-28 2004-09-02 Ngk Insulators, Ltd. Honeycomb structural body and die for forming honeycomb structural body by extrusion
WO2009069378A1 (en) * 2007-11-28 2009-06-04 Ngk Insulators, Ltd. Method for bonding joint sealing honeycomb structure
US20160069308A1 (en) * 2014-09-04 2016-03-10 Ngk Insulators, Ltd. Honeycomb filter
US20180099241A1 (en) * 2016-10-11 2018-04-12 Ngk Insulators, Ltd. Plugged honeycomb structure

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